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EP3349935A1 - Systèmes et procédé de surveillance d'une opération de soudage pulsé sur la base de l'analyse des signatures de soudage à l'aide de caractéristiques légales d'impulsion - Google Patents

Systèmes et procédé de surveillance d'une opération de soudage pulsé sur la base de l'analyse des signatures de soudage à l'aide de caractéristiques légales d'impulsion

Info

Publication number
EP3349935A1
EP3349935A1 EP16770177.0A EP16770177A EP3349935A1 EP 3349935 A1 EP3349935 A1 EP 3349935A1 EP 16770177 A EP16770177 A EP 16770177A EP 3349935 A1 EP3349935 A1 EP 3349935A1
Authority
EP
European Patent Office
Prior art keywords
signature
welding
weld
features
pulse
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP16770177.0A
Other languages
German (de)
English (en)
Other versions
EP3349935B1 (fr
Inventor
Stephen P. Ivkovich
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Illinois Tool Works Inc
Original Assignee
Illinois Tool Works Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Illinois Tool Works Inc filed Critical Illinois Tool Works Inc
Publication of EP3349935A1 publication Critical patent/EP3349935A1/fr
Application granted granted Critical
Publication of EP3349935B1 publication Critical patent/EP3349935B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0953—Monitoring or automatic control of welding parameters using computing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/09—Arrangements or circuits for arc welding with pulsed current or voltage
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode

Definitions

  • Pulsed transfer employed in pulsed metal inert gas (MIG) welding or pulsed tungsten inert gas (TIG) welding, for example, is a modified spray transfer process. Pulsed transfer periodically propels drops of molten metal across the arc to a workpiece.
  • MIG pulsed metal inert gas
  • TOG pulsed tungsten inert gas
  • a pulsed transfer system e.g., a pulsed MIG welding system, a pulsed TIG welding system, a pulsed welding system, etc.
  • a pulsed transfer system substantially as illustrated by and/or described in connection with at least one of the figures, as set forth more completely in the claims.
  • FIG. 1 shows an embodiment of a welding system according to the present disclosure.
  • FIG. 2 shows an embodiment of a circuit arrangement according to the present disclosure.
  • circuitry is "operable" to perform a function whenever the circuitry comprises the necessary hardware and code (if any is necessary) to perform the function, regardless of whether performance of the function is disabled or not enabled (e.g., by a user- configurable setting, factory trim, etc.).
  • FIG. 1 shows an embodiment of a welding system 10 according to the present disclosure.
  • the welding system 10 can include, for example, a computer 20, a power source 30 (e.g., a welding power source, a welding power supply, etc.), a welding torch 40 (e.g., a welding gun, a handheld welding torch, a robotic torch, a semi-automatic torch, etc.).
  • a power source 30 e.g., a welding power source, a welding power supply, etc.
  • a welding torch 40 e.g., a welding gun, a handheld welding torch, a robotic torch, a semi-automatic torch, etc.
  • the power source 30 provides current and/or voltage to a consumable electrode (e.g., tip of the feeder wire and/or material) of the torch 40 to form the arc 100.
  • the electrode delivers the current to the point of welding on the workpiece 100 through the arc 100.
  • the operator 80 controls the location and operation of the electrode by manipulating the torch 40 and triggering the starting and stopping of the welding process.
  • the power source 30 rapidly switches the welding output of the torch 40 from high peak current to low background current, or from high peak voltage to low background voltage. The high peak current pinches off a droplet of metal and propels it toward the weldment for good fusion.
  • the low background current maintains the arc, but is too low for metal transfer to occur. With no metal transfer, the weld puddle on the workpiece 110 gets a chance to cool. The process is repeated by the power source 30 as the operator 80 moves the torch 40 form the weld.
  • Pulse Forensic Features can include, for example, instantaneous frequency, pulse background slope, pulse droplet location, pulse droplet event magnitude, clear current values, one-droplet-per-pulse (ODPP) quality features, 'ideal pulse' correlation features, other correlation features, consistency metrics, etc.
  • the computer 20 and/or the power source 30 can determine whether potential weld fault conditions exist. In some embodiments, if potential weld fault conditions or weld fault conditions exist, the welding process and/or system can be stopped and/or alerts, indications, messages can be transmitted, displayed and/or heard.
  • the welding process and/or system can be configured to execute an operator-configured work instruction.
  • the advanced features parameters and/or measurements can be used to modify the weld process and/or system, or can be used to train or modify behavior in the operator 80.
  • FIG. 2 shows an embodiment of a circuit arrangement (e.g., component arrangement, device arrangement, and/or circuit arrangement) according to the present disclosure.
  • the circuit arrangement 120 illustrated in FIG. 2 is not comprehensive and can be supplemented with other components, devices, and/or circuits as known by one of skill in the art. Further, the circuit arrangement 120 shown in FIG. 2 can be part any of the devices of the system 100.
  • each of the computer 20, the power source 30, and/or the headwear 70 can include its own respective circuit arrangement 200.
  • the circuit arrangement 120 can include, for example, one or more processors 130, one or more memories 140 (e.g., one or more nontransitory memories), one or more communication devices 150 (e.g., wireless adapters, wireless cards, cable adapters, wire adapters, dongles, radio frequency (RF) devices, wireless communication devices, Bluetooth devices, IEEE 802.11 -compliant devices, WiFi devices, cellular devices, GPS devices, Ethernet ports, network ports, Lightning cable ports, cable ports, etc.), one or more input devices 160 (e.g., keyboards, mouse, touch pad, touch- sensitive screen, touch screen, pressure-sensitive screen, graphical user interface, user interfaces, buttons, microphone, etc.), and one or more output devices 170 (e.g., displays, screens, speakers, projectors, etc.).
  • the processor 130, the memory 140, the communication device 150, the input device 160, and/or the output device 170 can be connected to one or more buses 180 or other types of communication links.
  • the processor 130 can include, for example, one or more of the following: a general processor, a central processing unit, a digital filter, a microprocessor, a digital processor, a digital signal processor, a microcontroller, a programmable array logic device, a complex programmable logic device, a field-programmable gate array, an application specific integrated circuit, one or more cloud server(s) operating in series or in parallel, and a memory. Code, instructions, software, firmware and/or data may be stored in the processor 130, the memory 140, or both.
  • some of the code, instructions, applications, software, firmware and/or data can be hardwired (e.g., hardware implementations, hardwired into registers, etc.) and/or can be programmable.
  • Some embodiments of the present disclosure provide a method (e.g., an algorithmic method) of detailed processing or data analysis to extract feature information (feature extraction) from the voltage and current components of a weld signature (e.g., Weld Signature®) of a pulse mode MIG welding process or a pulse mode TIG welding process, for example.
  • a weld signature e.g., Weld Signature®
  • FIG. 3 shows a flow diagram of an embodiment of a method for pulse forensic analysis.
  • the inputs to the method can include, for example, one or more of the following: settings, the raw data, high-fidelity, sampled voltage and current signature components of a weld signature, and algorithm and/or information inputs.
  • the method isolates the data for each pulse to extract advanced features from each pulse.
  • the output of the method can include one or more advanced feature data sets (e.g., time-series format of the advanced feature data sets) that can be processed to determine whether potential weld fault conditions exist.
  • the use of advanced features instead or in addition to feature extraction can provide the welding system 10 with the capability of detecting potential weld fault conditions that would otherwise not be present by using only feature extraction for fault analysis. Further, in some embodiments, the use of advanced features provides greater resolution or granularity with respect to the fault condition analysis, thereby providing for the pinpointing of problems that would otherwise not be detectable or otherwise be pinpointed. By pinpointing problems, specific solutions can be identified and implemented. Moreover, the welding process can be stopped according to some embodiments to make changes in the welding process in view of the pinpointed problems or in view of the analysis of the advanced features.
  • the computer can be located physically by the power source or connected via a network to a local computer and/or a cloud computer and/or server.
  • the weld signature data including voltage and current between the tip of the torch 40 and the workpiece 110 as a function of time is stored.
  • FIG. 4 shows an embodiment of weld signature data including a voltage signature and a current signature over time from an actual welding process. The weld signature is stored and input into the process as shown in FIG.3 where the weld signature can be analyzed.
  • step 200 the method performs signature selection based on the weld signature data (e.g., current signature and voltage signature data) and process mode information (e.g., constant current mode, constant voltage mode, etc.).
  • weld signature data e.g., current signature and voltage signature data
  • process mode information e.g., constant current mode, constant voltage mode, etc.
  • the process mode information can determine, for example, which signature component to use for determining advanced feature information.
  • the voltage and current signature components of the welding process are acquired at a suitably high sampling rate (e.g., 1 kHz, 5kHz, 10kHz, 100kHz, etc.).
  • the sample rate is preferably 5kHz or higher to preserve signal fidelity.
  • the current is held substantially constant and the voltage is allowed to vary or to freely range within the context of the welding process. Since current is reliably controlled, pulse boundaries can be identified in the current signature including, for example, pulse start, transition, and pulse end. Since voltage is allowed to vary or to freely range within the context of the welding process, pulse forensic features can be identified in the voltage signature including a droplet event, slope, and droplet magnitude.
  • the voltage is held substantially constant and the current is allowed to vary or to freely range within the context of the welding process. Since voltage is reliably controlled, pulse boundaries can be identified in the voltage signature including, for example, pulse start, transition, and pulse end. Since current is allowed to vary or to freely range within the context of the welding process, pulse forensic features can be identified in the current signature including a droplet event, slope, and droplet magnitude.
  • the method performs a running average operation, based on an averaging time input, on one or more components of the weld signature.
  • the averaging time input can include a couple of pulses up to a hundred pulses; however, other numbers of pulses are also contemplated.
  • a local average of the signature component being held substantially constant is computed based on a moving window or running average.
  • the moving average window can be on the order of a quarter of a second, but other times can be selected to accommodate different pulse welding processes.
  • FIG. 4 shows, as dotted lines, examples of running averages for the voltage and the current according to some embodiments of the present disclosure.
  • the method performs individual pulse identification.
  • the running average of the weld component being held substantially constant is used as a baseline threshold by which to identify individual pulses including pulse start, transition, and pulse end for each pulse.
  • FIG. 4 shows an embodiment of a methodology used to identify individual pulse events in the weld signature components. Each individual pulse is identified and processed independently (syntactic analysis). Pulses are identified by comparing the rising and trailing edges to the running-average of the constant signature component (e.g., the voltage or current signature component that is being controlled to be like a predetermined pulse characteristic). The crossing of the running-average threshold can be used to identify, for example, a start time of the pulse, a transition time of the pulse, and an end time of the pulse.
  • the constant signature component e.g., the voltage or current signature component that is being controlled to be like a predetermined pulse characteristic
  • Droplet settings can be used to adapt the method (e.g., an algorithm) for expected details of droplet operation based on the process mode including, for example, slow pulse TIG, aluminum pulsed gas metal arc welding (PGMAW), etc.
  • droplet settings can indicate that the droplet occur between the lead inflection and the trailing inflection.
  • droplet settings can indicate that the droplet occur in a transition time zone around a transition time.
  • droplet settings can express expectations about the droplet such as the droplet being expelled during the background region which can be, for example, between the transition and the end of the pulse.
  • the droplet settings limit where the method and/or algorithm searches for the droplet event.
  • the method performs advanced features synthesis based on advanced feature settings.
  • multiple advanced feature time-series are derived from the list of individual pulse features captured in prior steps and combined through a weighted moving window averaging process over the length of the weld.
  • the resulting advanced features provide high fidelity details about variations in the pulsing process that can be used to detect weld fault conditions or to trigger alarms or the transmitting of notifications.
  • the nominal output rate of the pulse forensic advanced features is 100 Hz, but can be varied from as fast as once per pulse (which depends on the operating pulse rate of the welding machine and/or power supply 30) to as low as 10 Hz. Selection of the output rate for the advanced features is a classical tradeoff between measurement sensitivity and measurement statistical stability that can vary depending on the process and requirements for detection of weld faults.
  • a list of advanced features e.g., pulse forensic advanced features derived from pulse forensic analysis and the values corresponding to the advanced features are stored.
  • advanced features can include, for example, instantaneous frequency, which is fine accuracy measure of pulse rate. It can be determined on a pulse-by-pulse basis and the data can have a greater resolution or a finer granularity than a pulse.
  • advanced features can include, for example, a background slope which can be the slop of the background region of the pulse.
  • the background slope can be a background slope during a droplet event, and/or a slope between a lead inflection time and a trailing inflection time.
  • advanced features can include, for example, droplet location which can be, for example, a length of time from a start of the pulse to a start of a droplet event (e.g., a primary droplet event).
  • advanced features can include, for example, droplet magnitude which can be a magnitude of a projection of the droplet above a slope line (e.g., a background slope line).
  • a weld signature that includes a current signature and a voltage signature.
  • the advanced features synthesized from the weld signature include, for example, pulse boundaries from the current signature and droplet features from the voltage signature.
  • the droplet features from the voltage signature can include, for example, a slope of a droplet event and a droplet magnitude. Further droplet features can include, for example, a lead inflection time, a trailing inflection time, and a slope between the lead inflection time and the trailing inflection time.
  • the droplet features from the current signature can include, for example, a clear current value.
  • advanced features can include, for example, pulse peak statistics which can include, for example, a set of statistical measures derived (e.g., solely derived) from the characteristics of the pulse peak area.
  • advanced features can include, for example, pulse background statistics which can include, for example, a set of statistic measures derived (e.g., derived solely) from the characteristics of the pulse background area.
  • advanced features can include, for example, an optimal process quality feature in which it is determined how close to optimal (100 on a scale of 1 to 100) the operation of the pulsing process behaves.
  • advanced features can include, for example, wavelet pulse statistics that can include, for example, a set of statistical measures derived by wavelet analysis by comparing each individual pulse to a master reference or "mother" pulse form.
  • advanced features can include, for example, measures of the current at specific times related to the droplet location which represent the clear current of the pulsing process.
  • advanced features can include, for example, measures of the slopes related to pulse boundaries (e.g., a pulse starting point, a pulse transition, and/or a pulse ending point) or other specific locations in the timing of the pulse.
  • measures of the slopes related to pulse boundaries e.g., a pulse starting point, a pulse transition, and/or a pulse ending point
  • upper and/or lower limits can be one or more of the following: a fixed limit that is the same over the duration of a weld; a segmented limit that is constant over subsets of time over the duration of the weld; and a profiled limit that is changes (e.g., changes continuously) over the duration of the weld.
  • two methods can be used (e.g., in parallel) to detect faults and/or indicate faults.
  • Fault Type Upper Instantaneous Frequency
  • synchronous workflow events are events that occur, in an expected sequence, in the operation of the production welding process or job such as, for example, one or more of the following: job load, part start, first weld, last weld, part end, etc.
  • asynchronous workflow events are events that occur in the operation of the production welding process or job but which occur in an unexpected sequence when compared to the synchronous workflow events such as, for example, one or more of the following: shift change, lunch break, machine downtime, supervisor log-in, etc.
  • workflow instructions are the pre-specified operations that are desired to occur when specific events happen such as, for example, one or more of the following: send email and/or text information to a supervisor, play a video, sound an alarm, shutdown the welding machine (e.g., power supply 30), disable the manual welding torch 40, etc.
  • specific events happen such as, for example, one or more of the following: send email and/or text information to a supervisor, play a video, sound an alarm, shutdown the welding machine (e.g., power supply 30), disable the manual welding torch 40, etc.
  • pre-set workflow instructions can be set so that the system can respond uniquely to an indicated weld fault.
  • the instructions can be set so that they are applicable to any weld fault for any weld, or so that they only apply to a specific fault type on a specific weld location of a specific part of a specific job, or to any combination in between these conditions.
  • weld fault indications can be displayed and/or communicated in a number of ways. Faults can be consolidated such that if any fault occurs a "red light" alarm can be shown in the welding cell, on the welding machine, on a local operator display, on a fault indicator at a supervisor station, and/or on a remote display device. More specific fault information, including the type and character of the fault, can be displayed to the operator in real-time and historically through a graphical interface (e.g., a user graphical interface, a software graphical interface, a touch- sensitive graphical interface, etc.) in association with the source device, the part, the weld signature and/or weld report. Communication and display can be performed as an intrinsic part of the normal operation of the software and/or hardware of the system, or it can be caused by the execution of a specific workflow instruction that has been added to uniquely provide a desired form of communication and display.
  • a graphical interface e.g., a user graphical interface, a software graphical interface, a
  • weld fault indications can cause the system to take corrective action in a number of ways.
  • Faults can be consolidated such that if any fault occurs, a corrective action can be taken.
  • Corrective actions can include such operations as, for example, one or more of the following: lock the part clamping mechanism without automatically releasing a part until the part has been inspected; disable the manual welding torch until a supervisor resets the system; and/or automatically move the part into a scrap bin. More specific corrective actions, which are specific (and possibly limited) to the type and character of the fault, can be taken. Corrective action can be done as an intrinsic part of the normal operation of the software and hardware of the system, or it can be caused by the execution of a specific workflow instruction that has been added to uniquely provide a desired form of corrective action.
  • Some embodiments provide accurate, high-fidelity features that accurately represent variations in the pulse weld process which can, in turn, be used to detect weld defect conditions. [0073] Some embodiments are easily expandable or scalable to include additional features representing variations specific to a particular welding machine (e.g., a particular power supply), a particular welding process, or a particular fault mode.
  • Some embodiments integrates seamlessly into the normal flow and usage of weld monitoring tools and can be embodied in either power sources (e.g., welding power supplies) and/or in post-processing software or algorithms.
  • Some embodiments provide additional advanced features or sets of features that can be added as the knowledge of pulse process details and the effect of particular fault mode conditions develop.
  • Some embodiments provide for alternative means of synthesizing advanced feature time series that can be based on the selection of mode, max, min, outlier removal, and/or other means instead of a moving window averaging process or a weighted moving window averaging process.
  • the present method and/or system may be realized in hardware, software, or a combination of hardware and software.
  • the present methods and/or systems may be realized in a centralized fashion in at least one computing system, or in a distributed fashion where different elements are spread across several interconnected computing or cloud systems. Any kind of computing system or other apparatus adapted for carrying out the methods described herein is suited.
  • a typical combination of hardware and software may be a general-purpose computing system with a program or other code that, when being loaded and executed, controls the computing system such that it carries out the methods described herein.
  • Another typical implementation may comprise an application specific integrated circuit or chip.
  • Some implementations may comprise a non-transitory machine-readable (e.g., computer readable) medium (e.g., FLASH drive, optical disk, magnetic storage disk, or the like) having stored thereon one or more lines of code executable by a machine, thereby causing the machine to perform processes as described herein.
  • a non-transitory machine-readable (e.g., computer readable) medium e.g., FLASH drive, optical disk, magnetic storage disk, or the like

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Quality & Reliability (AREA)
  • Theoretical Computer Science (AREA)
  • Arc Welding Control (AREA)

Abstract

La présente invention concerne des systèmes (10) et un procédé de soudage. Le système de soudage (10) comprend une source d'alimentation (30), un ordinateur (20) et un chalumeau de soudage (40). L'ordinateur (20) et le chalumeau de soudage (40) peuvent être couplés de manière fonctionnelle à la source d'alimentation (30). La source d'alimentation (30) commande une alimentation en fil et un courant ou une tension vers le chalumeau de soudage (40). Lorsque le chalumeau de soudage (40) réalise un soudage pulsé, l'ordinateur (20) est configuré pour recevoir une signature de soudage. L'ordinateur (20) est configuré pour synthétiser des caractéristiques de la signature de soudage et analyser les caractéristiques pour chaque impulsion de la signature de soudage, afin de déterminer si des limites particulières ont été dépassées ou atteintes ou non. Si des limites particulières sont dépassées ou atteintes, une condition d'erreur de soudage est déclenchée et amène le système de soudage (10) à arrêter ou à modifier l'opération de soudage pulsé et/ou amène le système de soudage (10) à envoyer des communications relatives au déclenchement de la condition d'erreur de soudage.
EP16770177.0A 2015-09-14 2016-09-14 Système de soudage et procédé de surveillance d'une opération de soudage pulsé sur la base de l'analyse des signatures de soudage à l'aide de caractéristiques légales d'impulsion Active EP3349935B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201562218192P 2015-09-14 2015-09-14
US15/264,036 US11027352B2 (en) 2015-09-14 2016-09-13 Systems and methods for analyzing weld signatures using pulse forensic features
PCT/US2016/051579 WO2017048747A1 (fr) 2015-09-14 2016-09-14 Systèmes et procédé de surveillance d'une opération de soudage pulsé sur la base de l'analyse des signatures de soudage à l'aide de caractéristiques légales d'impulsion

Publications (2)

Publication Number Publication Date
EP3349935A1 true EP3349935A1 (fr) 2018-07-25
EP3349935B1 EP3349935B1 (fr) 2019-11-06

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US (1) US11027352B2 (fr)
EP (1) EP3349935B1 (fr)
CN (1) CN108349038B (fr)
CA (1) CA2996195A1 (fr)
MX (1) MX378682B (fr)
WO (1) WO2017048747A1 (fr)

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WO2017048747A1 (fr) 2017-03-23
CA2996195A1 (fr) 2017-03-23
EP3349935B1 (fr) 2019-11-06
CN108349038A (zh) 2018-07-31
US20170072497A1 (en) 2017-03-16
WO2017048747A8 (fr) 2017-04-20
CN108349038B (zh) 2020-11-06
US11027352B2 (en) 2021-06-08
MX378682B (es) 2025-03-10
MX2018003085A (es) 2018-05-07

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